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At twelve meters long, Frech's die-casting machines are truly gigantic, but their construction requires great precision. The usual measuring instruments, such as spirit levels or alignment scopes, are sometimes no longer sufficient. This German company finally decided to put its trust in the Faro Laser Tracker. From then on, there were no more problems, only solutions.
Oskar Frech GmbH + Co. KG is one of the market leaders in hot-chamber die-casting machines. These machines are used to cast materials such as zinc and magnesium. The parts produced include fittings, computer and cell phone casings, and toys such as Märklin's world-renowned model railroads. In the highly competitive market for hot-chamber die-casting machines, the German company occupies second place. These machines are used to manufacture complete aluminum engine blocks, such as Daimler's D8, or structural body parts for Audi. Typical products include gearboxes, instrument panels and escalator steps.
The dimensions of Frech's machines are truly gigantic. The hot-chamber variant can measure up to 17 meters in length, weigh up to 250 tons and produce a clamping force of 4,100 tons. A machine takes around 11 months to build, and the various parts are transported to the customer's site by special convoy. This makes the journey to the final destination a one-way trip: the return of defective machines to the production site in Schorndorf is totally out of the question, due to the enormous transport costs involved. What's more, it's not even certain that there's enough space available on the production floor. Before being assembled, the individual machine parts have to be stored in the customer's workshop to acclimatize. Only after this period is it checked that all parts fit together correctly, and that no signs of unnecessary wear are apparent. This procedure demonstrates the high level of precision required when building these giant machines.
Frech has been using a Faro measuring arm since 2006. This year, they ordered a new measuring device from Faro, the Laser Tracker Vantage. This decision was prompted mainly by the regular problems encountered by an automotive customer with his machine. After switching to a different mold, the machine's symmetry no longer matched, and the guide columns no longer fitted precisely into their housings and stumbled forward. Frech's technicians checked the machine several times, but were never able to find the cause of the malfunction due to the complex assembly conditions. After the mold had been changed, the columns continued to seize when retracted. The company finally decided to call in a Faro technician to discuss the dimensions to be measured and the practical combination of form and position tolerances. Thanks to Faro's Laser Tracker, he was able to quickly detect the source of the fault. This performance left a memorable impression on Frech, and the Faro Laser Tracker Vantage immediately found its way onto the current shopping list.
Since then, Faro measuring systems have been used not only by Frech and its suppliers, but also by the customer during machine assembly. The free space around the machine is often very limited, leaving little room for measurements and measuring equipment. This is why we are currently considering combining the measuring arm and Laser Tracker into a new system, the TrackArm. The TrackArm combines the long range and high accuracy of the Laser Tracker with the flexibility and reliability of the FaroArm. And here's the main advantage: the measuring arm can be quickly repositioned within the laser tracker's measuring range. In this way, the arm remains in the same coordinate system at all times, enabling it to reach points outside the Tracker's field of vision. This means that technicians can carry out measurements at very close range, enabling them to inspect large components without any problems. Wolfgang Schöben, Head of Quality Management at Frech, couldn't do without the Laser Tracker: " We have to find and resolve any errors or inaccuracies on site, as we transport the machine to the customer by special convoy. There is no return possible. "In spring 2013, Frech also launched a quality offensive with its suppliers and defined uniform, global measurement methods to put an end to recurring quality problems. Faro's measuring equipment is the recurring element of this strategy, as Frech requires that the parts supplied are also measured with Faro's equipment. If this is not possible, the Schorndorf site offers a measurement service.
In the meantime, Frech carries out rapid and precise measurements in every area of production. And these checks are carried out during the construction phase. This means that corrections can be made before it's too late and costly interventions are required at a later date. " This process is crucial, as deviations in a single component can have repercussions on the statics of the entire machine, underlines Mr. Schöben. In such a case, the components manufactured subsequently must be adapted to the deviations. "This puzzle is costly and can have serious repercussions on the combination of components.
In the past, Frech measured and adjusted components using conventional measuring devices such as spirit levels, micrometers or alignment glasses. " Faro's measuring equipment saves us many hours of workassures Mr Schöben. What's more, automotive customers ask us for detailed test reports. And thanks to Faro's systems, we can generate them in the blink of an eye. "
About Oskar Fresh GmbH Co&Kg:
Right from the start, passion played a significant role at Oskar Frech GmbH + Co. KG. And it's thanks to this that the allameande toolmaking company, located in Schorndorf-Weiler near Stuttgart, has grown to become one of the world's leading specialists in cold-casting technology, with 700 employees. Frech's product range meets all customer requirements. Companies offering zinc, magnesium or aluminum die-casting find tailor-made solutions at Frech, from the production of small die-cast parts to engine blocks and body components.
Learn more: https://www.faro.com/fr-fr/actualite-et-evenements/cas-d-application/2013/12/12/le-faro-laser-tracker-optimise-la-symetrie-des-machines-chez-oskar-frech
